Polysius
Optimizing combustion and heat recovery.
Reduced fuel demand.
Long-term results.
Modern pyroprocessing solutions that unlock hidden potential in your existing plant
Pyroprocessing is the thermal heart of the cement plant. Its performance directly defines fuel consumption, clinker quality, emissions and overall plant stability. Aging burners, coolers or preheater components often limit alternative fuel usage, increase heat losses and reduce operational flexibility.
With thyssenkrupp Polysius Pyroprocessing Modernizations, cement producers can level up kiln performance without building new. Targeted upgrades to burners, coolers, preheaters and auxiliary systems unlock measurable efficiency gains, stabilize operation and reduce OPEX – even in existing and third-party installations.
Whether your challenge is fuel substitution, rising energy costs or unstable kiln operation: our modular modernization approach delivers fast ROI with minimal downtime.
UP TO
25%
OPEX REDUCTION
UP TO
20%
capacity increase
UP TO
50%
higher lifetime
UP TO
15%
HIGHER AVAILABILITY
UP TO
20%
power savings
Pyroprocessing Portfolio
- dopol® 90 Preheater & Calciner
- Used for preheating and calcining of kiln feed
- High production capacities with low operating costs
- Low capital expenditure
- Flexible concepts for 12,000 tpd with low pressure drop
- Rotary Kiln
- Statically determined support configuration
- Direct drive system
- Stable conditions and higher availability of the kiln line
- Automatically adapting rollers for optimal operating conditions.
- Graphite & Pneumatic Seals
- Seal off the kiln process from leak air
- Maximum process reliability
- No additional kiln-modifications are necessary
- Aircooled sealing casing minimizes thermal effects
- polflame® VN Burner
- Second-generation model thyssenkrupp
- Designed to enable any changes in fuels/substitution rate/ capacity increases without major modifications
- Up to 100% alternative fuel substitution with stable flame shape
- polytrack® eco Clinker Cooler
- Achieves 76% cooling efficiency
- Seamless material transport
- Delivers low clinker outlet temperature
- Operates with a power consumption of less than 4,5 kWh per ton of clinker
Your Key Benefits – measurable impact
Up to 20% capacity increase
Optimized burners, preheaters and coolers reduce specific heat consumption.
Up to 50% higher lifetime
Up to 15% higher availability
Up to 20% power savings
Case Study
Pyroprocessing Modernization
at Phoenix Cement
At the Phoenix Cement plant in Beckum, thyssenkrupp Polysius implemented the world’s first installation of the new polytrack® eco clinker cooler, modernizing the existing cooling system within the existing building structure.
The plant operated at a nominal capacity of 1,400 tpd. While the existing grate cooler was functional, high maintenance effort and increasing alternative fuel rates (>80%) led to unstable operating conditions. To minimize investment costs, the upper housing, base frame and roll crusher were reused, while the housing was modified and elevated to integrate the longer cooler.
The modernization was executed during the winter shutdown 2021/22 and completed within 38 days.
KEY BENEFITS
- Reduced specific heat consumption
- Lower electrical power demand
- Stable kiln operation at high alternative fuel rates
- Reuse of existing structures, reduced CAPEX
- Fast ROI
FAQ
What makes the polflame® VN burner so flexible regarding fuel types?
The polflame® VN features a maintenance-free nozzle adjustment system that allows operators to adjust swirl and primary air velocity during operation. This enables the efficient use of alternative fuels (such as waste-derived fuels or low-grade coal) without compromising clinker quality or kiln stability.
What are the primary advantages of the polytrack® eco clinker cooler?
As a next-generation cooler, the polytrack® eco combines maximum thermal efficiency with extremely low maintenance requirements. Its design is focused on high heat recuperation and operational reliability.
Can I upgrade my existing clinker cooler to a roll crusher?
Yes. We can convert your clinker crusher from a hammer crusher to a roll crusher. Roll crushers are more wear-resistant, provide reliable crushing with no oversize material, and require less maintenance as they use electromechanical drives instead of complex hydraulic systems.
Learn more about optimizing your plant: Modernization Portfolio Deep Dive
In a rapidly evolving industrial landscape, staying competitive means getting more out of the assets you already have. During our upcoming 30–45 minute virtual session, we will show how targeted modernizations can unlock hidden performance potential across your plant, boosting throughput, improving efficiency, and reducing OPEX.
Join our experts from thyssenkrupp Polysius as they provide a compact, high‑value overview of modernization levers across the entire process chain: crushing, raw grinding, clinker grinding, pyroprocessing, and laboratory automation.
YOU’LL GAIN INSIGHTS INTO:
- How modernization audits reveal hidden inefficiencies
- What typical performance increases look like
- Which upgrade paths deliver the fastest ROI
WHAT TO EXPECT:
- A practical modernization overview
- Real improvement examples from global plants
- Q&A with our specialists
Rolf Rieger
Expert Clinker Cooling
Jens Opperbeck
Head of Pyroprocessing – Service
Get in Contact
About us
thyssenkrupp Polysius is one of the leading suppliers of technologies and automation solutions for the decarbonization of the cement and lime industry and, increasingly, for other industries. With more than 160 years of experience, we set standards in the development of innovative technologies and services, as well as a comprehensive and customized service offering that enables sustainable and economical production.
Our services are not only tailored to our own products, but also cover installations from third-party suppliers. Thanks to close cooperation with customers and partners, we are able to meet the specific challenges of our customers and offer them optimal service. This special commitment, coupled with decades of expertise, makes thyssenkrupp Polysius a reliable partner on the road to a sustainable future.
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